Disposal of drums of waste paint and coating is a necessary evil for anyone in the industrial coating or finishing business, but is especially true for coil coaters.
Hazardous waste disposal costs vary, but average on the order of $130-$150 per drum. Therefore, minimizing the number of drums to be disposed of is essential, both for financial and environmental reasons.
Where Does Waste Paint & Coating Come From?
In our blog, "Add the PCM to Your Coil Coating Technology to Trim Costs," we noted:
“…the primary source of partial drums and dead paint is excessive system fill volume – the number of gallons of paint required to be in the pump, the hoses, and the pan in order to keep the system coating. And of these, the greatest volume is in the pan. It is the volume of paint required to get enough depth to keep the pickup roller from starving out.
When the job is finished, this is the volume of paint left over – either as a partial drum, or as dead paint.”
Waste Accumulates – Fast!
If left to accumulate, these partial drums can take up a great deal of space. On recurring colors, they have to be saved for the next run of that product, but on waste paint, these drums have to be consolidated – both to save space and to prepare for disposal. And in the case of custom colors, by definition, all of the leftover paint at the end of the job is waste.
Even after efforts to reduce pan size, system fill volumes of 8–10 gallons are common. That’s 8–10 gallons of waste paint for every custom color job! That means four custom color jobs per drum of waste paint. At $150/drum for waste disposal, that’s $37.50 in dead paint disposal cost that has to be added to the price of every custom color job.
Enter SCS’ Profile Correction Module (PCM).
With the PCM, system fill volumes (including pan, pumps, hoses, etc.) of less than four gallons are common.
So let’s assume that your pan size reduction efforts have resulted in a total system fill volume of eight gallons. This is reduced to fur gallons by the implementation of the PCM – which represents a 50% reduction. Using the example above, this would reduce your dead paint disposal cost from $37.50 each to just $18.75 each. This may not seem like much, but if you run just one custom color job per day, this adds up to nearly $5,000 per year.
There are a host of other savings that come from this effort. To begin with, the extra paint that has to be purchased for custom colors, just to support the fill volume is also reduced by 50%. Moreover, the improved film control offered by the PCM can make total paint estimates much more accurate and reliable, meaning that you buy only the paint that you need – and this mean less waste.
In addition, the minimum partial drum volume for standard colors is also reduced by 50%. Though these can be used on the next run, this means that the waste paint that is generated for these colors (for whatever reason) will also be reduced.
A 10% Reduction
Across the operation, if just 20% of the partial drums generated in a year are reduced by 50%, the result will be a 10% net reduction in waste paint disposal costs. But in addition to offering significant operational cost savings, this is also an environmentally friendly solution.
At the risk of being trite – it’s a win-win!
Download our free Coil World Article to learn more about the module and how it can help your business.